METRODE

A133

WELDING CONSUMABLES

25%Cr SUPERDUPLEX - ZERON® 100

Alloy type Microstructure

25%Cr superduplex ferritic-austenitic stainless steels Multipass welds in the as-welded condition consist of a
matching the proprietary Zeron® 100 alloy. duplex austenite-ferrite microstructure with an
approximate 30-60% ferrite level, depending on heat
Materials to be welded input/cooling conditions.
Matching
Welding guidelines
wrought: cast:
UNS S32760 UNS J93380, DIN 1.4508 Preheat not generally required. Interpass temperature
DIN 1.4501 ASTM A890 6A, 150°C max. Heat input in the range 1.0–2.0 kJ/mm
ASTM A182 F55 ACI CD3MWCuN (depending on material thickness) should be acceptable
but most codes restrict the max to 1.5 or 1.75kJ/mm.
Other superduplex, including
wrought: PWHT
UNS S32750, 2507 (Sandvik/Avesta), UR47N (CLI)
Although welds in wrought duplex stainless steels are
UNS S32550, S32520, UR52N+ (CLI), Ferralium
almost always left in the as-welded condition, major
SD40 (Meighs)
repairs to castings are generally specified in the solution
UNS S39274, DP3W (Sumitomo), UNS S32950, 7-Mo
treated condition. Experience has indicated good
Plus (Carpenter)
cast:
properties following 1120°C/3-6h + water quench.
UNS J93404, DIN 1.4469
ASTM A890 5A, ACI CE3MN Additional information
Further information on the welding of Zeron® 100 is
Applications available in the Metrode Technical Profile on duplex
®
Zeron 100 has an exceptional combination of strength and superduplex.
and resistance to corrosion and erosion in a wide range
of aggressive media. The presence of Cu+W provides Related alloy groups
superior resistance to sulphuric and hydrochloric acids 2507 superduplex (data sheet B-62) and matching
when compared to similar alloys without these consumables for casting repair (solution annealed)
additions. Offshore applications exploit the high applications.
resistance to pitting and stress-corrosion cracking in
seawater. It is also highly resistant to caustic alkalis and Products available
phosphoric acid. Service temperature range is usually
limited to –50°C to 280°C, the upper limit owing to Process Product Specification
thermal instability ("450°C" and sigma embrittlement). MMA ®
Zeron 100XKS BS EN E25 9 4 NLB
®
It is widely used in oil and gas production and process TIG/MIG/SAW Zeron 100X BS EN 25 9 4 NL
pipework, risers, manifolds, pressure vessels, valves, SAW flux SSB BS EN SA AF 2
pumps, desalination plant, systems for flue-gas LA491 BS EN SA FB 2
desulphurisation (FGD) and also in the mining, Supercore
FCW --
chemical and pharmaceutical industries. Zeron® 100 Z100XP
wires are also used for joining supermartensitic stainless
steels.

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 METRODE
A134

WELDING CONSUMABLES

General Data for all Zeron® 100 MMA Electrodes

Storage 3 hermetically sealed ring-pull metal tins per carton, with unlimited shelf life. Direct use from tin is satisfactory
for longer than a working shift of 8h. Excessive exposure of electrodes to humid conditions will cause some
moisture pick-up and increase the risk of porosity.
For electrodes that have been exposed:
Redry 200 – 300°C/1-2h to restore to as-packed condition. Maximum 400° C, 3 cycles, 10h total.
Storage of redried electrodes at 50 – 200°C in holding oven or heated quiver: no limit, but maximum 6 weeks
recommended. Recommended ambient storage conditions for opened tins (using plastic lid): < 60% RH, > 18°C.

Fume data Fume composition, wt % typical:

Fe Mn Ni Cr Cu Mo V F OES (mg/m3)
7 6 1 7 0.5 0.2 <0.1 28 0.7

ZERON® 100XKS Basic pipe-welding electrode for superduplex

Product description Basic coated all-positional MMA electrode for welding Zeron® 100 and other superduplex alloys for service in the
as-welded condition. This electrode is overmatching with respect to nickel content to achieve correct austenite-
ferrite microstructural phase balance. It is designed for the most demanding vertical and overhead welding
positions such as fixed pipework qualified in the ASME 6G position.
Fully alloyed matching Zeron® 100 core wire including W and Cu. Moisture resistant flux technology.
Recovery is about 105% with respect to core wire, 65% with respect to whole electrode.

Specifications AWS A5.4 E2595-15

BS EN 1600 E 25 9 4 N L B 4 2
Weir Materials MDS 12809/08
Approvals ABS, DNV

ASME IX Qualification QW432 F-No 5, QW442 A-No 8

Composition C Mn Si S P Cr Ni Mo W Cu N PREN PREW

(weld metal wt %) min -- -- -- -- -- 24.0 9.0 3.5 0.5 0.5 0.2 40 40
max 0.03 1.0 1.0 0.01 0.03 26.0 10.0 4.0 1.0 1.0 0.3 -- --
typ 0.025 0.9 0.5 0.005 0.02 25 9.3 3.6 0.7 0.7 0.23 41 42
Pitting resistance equivalent PREN = Cr + 3.3Mo + 16N
Pitting resistance equivalent PREW = Cr + 3.3Mo + 1.65W + 16N

All-weld mechanical As welded min typical

properties Tensile strength MPa 760 800-950
0.2% Proof stress MPa 550 650-750
Elongation on 4d % 15 30
Elongation on 5d % 20 22-27
Reduction of area % -- 40-45
Impact energy - 20°C J -- > 55
- 50°C J -- > 40
Hardness HV -- 270-320

Operating parameters DC +ve

ø mm 2.5 3.2 4.0 5.0

min A 50 70 100 130
max A 75 95 155 210

Packaging data ø mm 2.5 3.2 4.0 5.0

length mm 300 350 350 350
kg/carton 12.0 14.1 13.5 13.5
pieces/carton 696 360 270 172

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 METRODE
A135

WELDING CONSUMABLES

ZERON® 100X Solid welding wire for superduplex

Product description Solid wire for TIG, MIG and SAW.

For applications where Zeron® 100X wire is to be used for welding supermartensitic stainless steels it is possible
for wire to be supplied with a total hydrogen content of 3ppm maximum.

Specifications AWS A5.9 ER2594

BS EN ISO 14343-A 25 9 4 N L (prefix W=TIG, G=MIG, S=SAW)
Weir Materials MDS 12809/07
Approvals ABS, DNV (TIG and SAW in conjunction with SSB flux)

ASME IX Qualification QW432 F-No 6, QW442 A-No 8

Composition C Mn Si S P Cr Ni Mo W Cu N PRE PRE

N W
(wire wt %) min -- -- -- -- -- 24.0 9.0 3.5 0.5 0.5 0.2 40 40
max 0.03 1.0 1.0 0.01 0.03 26.0 10.0 4.0 1.0 1.0 0.3 -- --
typ 0.015 0.7 0.4 0.002 0.02 25 9.3 3.7 0.6 0.7 0.23 41 42

All-weld mechanical Typical values as welded min TIG MIG SAW TIG +160°C
properties Tensile strength MPa 760 870 860 885 769
0.2% Proof stress MPa 550 695 645 700 523
Elongation on 4d % 15 36 25 26 39
Elongation on 5d % 20 32 23 24 34
Reduction of area % -- 68 28 48 72
Impact energy -50°C J -- 130 60 40 --
-75°C J -- >100 -- -- --
Hardness cap/mid HV -- 290 290 290 --

Typical operating TIG MIG SAW

parameters Shielding Argon Ar/He/CO2 SSB flux
Current DC- pulsed DC+
Diameter 1.6/2.4mm 1.2mm 1.6mm
Voltage 100A, 12V 180A, 28V 350A, 30V

Packaging data ø mm TIG MIG SAW

0.8 -- To order --
1.0 -- To order --
1.2 -- To order --
1.6 2.5kg tube -- 25kg coil
2.0 2.5kg tube -- --
2.4 2.5kg tube -- 25kg coil
3.2 2.5kg tube -- --

Fume data MIG fume composition (wt %) (TIG and SAW fume negligible)
Fe Mn Cr3 Ni Mo Cu OES (mg/m3)
28 10 22 8 2 1.3 2.3

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 METRODE
A136

WELDING CONSUMABLES

SSB FLUX Sub-arc flux

Product description Agglomerated basic non-alloying flux for submerged arc welding.

Specifications DIN 32522 BFB6 63353 DC8M

BS EN 760 SA AF2 DC

ASME IX Qualification QW432 F-No -, QW442 A-No -

Composition C Mn Si S P Cr Ni Mo Cu W N
(typical) Zeron® 100X wire 0.015 0.7 0.4 0.002 0.023 25 9.3 3.7 0.7 0.7 0.23
Deposit 0.02 0.6 0.4 0.002 0.02 24.5 9.3 3.6 0.7 0.7 0.21

All-weld mechanical Typical values as welded min SAW

properties with Tensile strength MPa 750 890
®
Zeron 100X wire 0.2% Proof stress MPa 550 700
Elongation on 4d % -- 25
Elongation on 5d % 20 24
Reduction of area % -- >40
Impact energy - 50°C J -- 40
Hardness HV -- 290

Operating parameters Current: DC +ve ranges as below:

ø mm amp-volt range typical stickout

1.6 200-350A, 27-31V 300A, 28V 20-25mm
2.4 250-450A, 28-32V 350A, 29V 20-25mm

Packaging data Metrode SSB Flux is supplied in sealed moisture resistant 20kg metal drums. Preferred storage conditions for
opened drums: < 60%RH, > 18°C. If the flux has become damp or has been stored for a long period, it should be
redried in the range 250-400°C/1-3h.

LA491 FLUX Sub-arc flux

Product description Agglomerated fluoride-basic non-alloying flux for submerged arc welding.

Specifications DIN 32522 B FB 6 55455 AC 8

BS EN 760 SA FB 255 AC

ASME IX Qualification QW432 F-No -, QW442 A-No -

Composition C Mn Si S P Cr Ni Mo Cu W N
(typical) Zeron® 100X 0.015 0.7 0.4 0.002 0.02 25 9.3 3.7 0.7 0.7 0.23
wire
Deposit 0.02 0.6 0.4 0.002 0.02 24.5 9.3 3.6 0.7 0.7 0.21

All-weld mechanical Typical values as welded min SAW

properties with Tensile strength MPa 750 890
®
Zeron 100X wire 0.2% Proof stress MPa 550 700
Elongation on 4d % -- 25
Elongation on 5d % 20 24
Reduction of area % -- >40
Impact energy - 50°C J -- 40
Hardness HV -- 290

Operating parameters Current: DC +ve ranges as below:

ø mm amp-volt range typical stickout

1.6 200-350A, 27-31V 300A, 28V 20-25mm
2.4 250-450A, 28-32V 350A, 29V 20-25mm

Packaging data Metrode LA491 Flux is supplied in sealed moisture resistant 20kg metal drums. Preferred storage conditions for
opened drums: < 60%RH, > 18°C. If the flux has become damp or has been stored for a long period, it should be
redried in the range 300-350°C/1-3h.

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 METRODE
A137

WELDING CONSUMABLES

SUPERCORE Z100XP Rutile flux cored wire for superduplex stainless steel

Product description Flux cored wire made with an alloyed stainless steel sheath and rutile flux system. Supercore Z100XP combines
easy operability, high deposit quality for both positional pipework and downhand welding. Metal recovery is
about 90% with respect to the wire.

Specifications There are no national specifications for this wire.

ASME IX Qualification QW432 F-No --, QW442 A-No --

Composition C Mn Si S P Cr Ni Mo Cu W N PRE PREW

N
(weld metal wt %) min -- -- -- -- -- 24.0 8.5 3.5 0.5 0.5 0.2 40 40
max 0.04 1.5 1.0 0.01 0.03 26.0 10.0 4.0 1.0 1.0 0.3 -- --
typ 0.03 1.0 0.5 0.005 0.02 24.5 9.1 3.7 0.6 0.6 0.22 41 42
Pitting resistance equivalent PREN = Cr + 3.3Mo + 16N
Pitting resistance equivalent PREW = Cr + 3.3Mo + 1.65W + 16N

All-weld mechanical As welded min typical

properties Tensile strength MPa 750 880
0.2% Proof stress MPa 550 690
Elongation on 4d % -- 27
Elongation on 5d % 20 25
Reduction of area % -- 33
Impact energy -20°C J -- 40
-50°C J -- 32
Hardness HV -- 280
HRC -- 26

Operating parameters Shielding gas: 80%Ar-20%CO2 at 20-25l/min. Proprietary gases may be used but argon should not exceed 85%.
Current: DC+ve ranges as below for Ar-20%CO2:
ø mm amp-volt range typical stickout
1.2 120 – 250A, 22 – 34V 180A, 29V 15 – 20mm

Packaging data Spools vacuum-sealed in barrier foil with cardboard carton: 15kg
The as-packed shelf life is virtually indefinite.
Resistance to moisture absorption is high, but to maintain the high integrity of the wire surface and prevent any
possibility of porosity, it is advised that part-used spools are returned to polythene wrappers.
Where possible, preferred storage conditions are 60% RH max, 18°C min.

Fume data Fume composition (wt %)

Fe Mn Ni Cr3 Cr6 Cu F OES (mg/m3)
14 10 1.5 5 5 <1 5 1.0

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